Hybrid mattress core assemblies

ABSTRACT

Mattress assemblies including a hybrid mattress core assembly having a bilayer structure including a fiber layer laminated to a foam layer. Also disclosed are mattress assemblies including a hybrid mattress core assembly having a trilayer structure including a fiber layer sandwiched between first and second foam layers.

BACKGROUND

The present disclosure generally relates to mattress assemblies, and more particularly, to mattress assemblies including hybrid mattress core assemblies including a laminate structure of one or more foam layers and one or more fiber layers.

Mattress assemblies, such as those formed of polyurethane foam, latex foam, and the like, with or without coil springs, are generally well known in the art. Typical mattress assembly constructions include a mattress core and an optional peripheral side rail assembly about the mattress core that are encapsulated within a fabric such as a quilted fabric. The mattress core and side rail assembly generally have a thickness that approximates the overall thickness of the mattress assembly. The composition of the mattress core generally defines the level of comfort provided to an end user. Problems associated with current mattress cores include overall weight issues, costs to manufacture, and availability of materials. Also, the mattress core typically needs to provide a degree of air flow to prevent heat build-up during use as well as provide the desired level of support.

BRIEF SUMMARY

Disclosed herein mattress assemblies and upholstery layers for mattress assemblies. In one or more embodiments, a one-sided mattress assembly includes a mattress core including a bilayer laminate structure consisting of a foam layer and a fiber layer, wherein the foam layer is defined by one or multiple stackedly arranged foam layers and wherein the fiber layer is defined by one or multiple stackedly arranged fiber layers, wherein the mattress core is oriented such that the foam layer is proximate to a sleeping surface of the mattress assembly and the fiber layer is distally located to the sleeping surface.

In one or more embodiments, a two-sided mattress assembly includes a mattress core comprising a trilayer laminate structure consisting of a fiber layer sandwiched between first and second foam layers, wherein the fiber layer is defined by one or multiple stackedly arranged fiber layers, wherein the first foam layer is defined by one or multiple stackedly arranged foam layers, and wherein the second foam layer is defined by one or multiple stackedly arranged foam layers.

In one or more embodiments, a mattress assembly includes a mattress core; an upholstery layer overlaying the mattress core including a bilayer laminate structure consisting of a foam layer and a fiber layer, wherein the foam layer is proximately located to a sleeping surface of the mattress assembly and the fiber layer is distally located to the sleeping surface; and a fabric ticking layer encapsulating the mattress core and the upholstery layer to form the mattress assembly.

The disclosure may be understood more readily by reference to the following detailed description of the various features of the disclosure and the examples included therein.

BRIEF DESCRIPTION OF THE DRAWINGS

Example embodiments of the invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout, and wherein:

FIG. 1 illustrates a cross sectional view of a bilayer mattress core for use in a mattress assembly in accordance with an embodiment of the present disclosure;

FIG. 2 illustrates a cross sectional view of a trilayer mattress core for use in a mattress assembly in accordance with an embodiment of the present disclosure; and

FIG. 3 pictorially illustrates a cross sectional view of a portion of a mattress core including a foam layer laminated to a fiber layer in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION

Disclosed herein are mattress assemblies including a hybrid mattress core assembly formed of a bilayer or trilayer laminate structure including one or more foam layers and one or more fiber layers within the laminate structure. Reference to the term's “bilayer” and “trilayer” generally refers to the collective type of material utilized in each of the layers. For example, a bilayer structure includes two layers, wherein one or more layers of foam are stackedly arranged to define one layer and one or more layers of fibers are stackedly arranged to define the second layer. The layers can be laminated to one another to form the mattress core. The trilayer structure includes three layers, wherein the one or more fiber layers are sandwiched between the one or more fiber layers. As will be described in greater detail below, the different layers defining the foam layer or the fiber layer in the bilayer or trilayer structure can be the same or different and configured with different properties. Still further, the bilayer or trilayer structure can be utilized to define a mattress core and/or an upholstery layer. The mattress core is generally referred to as the support layer whereas the upholstery layer, which covers the mattress core, is referred to as the comfort layer.

Reference to hybrid mattress core assemblies can be utilized in one-sided mattress or two-sided mattress constructions. For one sided mattress constructions, a bilayer laminate structure is utilized, wherein the one or more fiber layers are oriented to be distal to the sleeping surface and the one or more foam layers are proximal to the sleeping surface. For two-sided mattress constructions, which can be periodically flipped as may be desired by the user, the trilayer laminate structure is utilized, wherein the one or more fiber layers are sandwiched between one or more foam layers. In this construction, the foam layer is proximal to the sleeping surface regardless of mattress orientation.

In one or more embodiments, the hybrid mattress core assembly is greater than 80% of the overall height of the mattress. In other embodiments, the hybrid mattress core assembly is greater than 90% of the overall height of the mattress, and in still one or more embodiments, the hybrid mattress core assembly is greater than 95% of the overall height of the mattress assembly. In embodiments where the hybrid mattress core assembly is less than an overall thickness of the mattress assembly, the mattress assembly can include additional layers overlaying and/or underlaying and/or encapsulating the hybrid mattress core assembly, e.g., a microcoil layer, a viscoelastic foam layer, a perforated foam layer, a fire-retardant layer, a quilt layer, sock layer, and the like.

Alternatively, the hybrid mattress core assembly can be seated within a foam bucket assembly, wherein the foam bucket assembly generally includes a planar base foam layer and upright foam sidewalls extending about a perimeter of the planar base foam layer to define a cavity, wherein the hybrid mattress core assembly is seated within the cavity. One or more foam layers can overlay the hybrid mattress core assembly and the bucket assembly.

The mattress assembly can further include a side rail assembly including foam, coils, and combinations thereof about the perimeter of the hybrid mattress core assembly to provide a desired amount of edge support.

Regarding the upholstery layer, a hybrid foam-fiber bilayer laminate structure can be utilized to provide a desired level of support. The upholstery layer is seated onto the mattress core can covered and the resulting mattress assembly is covered in fabric, which is also referred to as ticking. In these constructions, the foam layer is configured to be proximal to the sleeping surface.

For the purposes of the description hereinafter, the terms “upper”, “lower”, “top”, “bottom”, “left,” and “right,” and derivatives thereof shall relate to the described structures, as they are oriented in the drawing figures. The same numbers in the various figures can refer to the same structural component or part thereof. Additionally, the articles “a” and “an” preceding an element or component are intended to be nonrestrictive regarding the number of instances (i.e., occurrences) of the element or component. Therefore, “a” or “an” should be read to include one or at least one, and the singular word form of the element or component also includes the plural unless the number is obviously meant to be singular.

Spatially relative terms, e.g., “beneath,” “below,” “lower,” “above,” “upper,” and the like, can be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures.

The following definitions and abbreviations are to be used for the interpretation of the claims and the specification. As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having,” “contains” or “containing,” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a composition, a mixture, process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but can include other elements not expressly listed or inherent to such composition, mixture, process, method, article, or apparatus.

As used herein, the term “about” modifying the quantity of an ingredient, component, or reactant of the invention employed refers to variation in the numerical quantity that can occur, for example, through typical measuring and liquid handling procedures used for making concentrates or solutions. Furthermore, variation can occur from inadvertent error in measuring procedures, differences in the manufacture, source, or purity of the ingredients employed to make the compositions or carry out the methods, and the like.

It will also be understood that when an element, such as a layer, region, or substrate is referred to as being “on” or “over” another element, it can be directly on the other element or intervening elements can also be present. In contrast, when an element is referred to as being “directly on” or “directly over” another element, there are no intervening elements present, and the element is in contact with another element.

Turning now to FIG. 1 , there is shown a cross sectional view of a hybrid mattress core assembly 10 having a bilayer laminate structure for use in a one-sided mattress assembly. The hybrid mattress core assembly 10 includes foam layer 12 defined by three foam layers designated by reference numerals 14, 16, 18, although a lesser or a greater number of foam layers can be used and fiber layer 20, which is defined by three foam layers designated by reference numerals 22, 24, 26, although a lesser or a greater number of foam layers can be used. The foam layer 12 can have a bottommost planar surface that is laminated to an uppermost planar surface of the fiber layer 20, wherein the resulting mattress assembly is oriented such that the foam layer is proximate to the sleeping surface and configured as a one side mattress assembly. The bilayer laminate structure can be used to define the upholstery layer albeit at relatively smaller thicknesses. The hybrid upholstery layer can overlay any mattress core including but not limited to the hybrid mattress core as described herein.

FIG. 2 illustrates a cross sectional view of a hybrid mattress core 50 having a trilayer laminate structure for use in a two-sided mattress assembly. The hybrid mattress core assembly 50 includes two foam layers 52, 54, wherein each foam layer is defined by three foam layers designated by reference numerals 56, 58, 60 and 62, 64, 66, respectively, although a lesser or a greater number of foam layers can be used and a fiber layer 70 sandwiched between foam layers 52, 54, wherein the fiber layer 70 is defined by three fiber layers designated by reference numerals 72, 74, 76, although a lesser or a greater number of foam layers can be used. The foam layer 52, 54 include at least one planar surface that is laminated to a corresponding planar surface of the fiber layer 70.

FIG. 3 pictorially illustrates a hybrid mattress core having a bilayer laminate structure including a single layer of foam laminated to a single layer of vertically oriented fiber. Each layer was at a thickness of 3.5 inches.

The process of laminating the foam and fiber layers to form the hybrid mattress core assembly is not intended to be limited. The application of adhesives, with or without pressure, on respective foam and fiber surfaces that are to be laminated together can be used. Other methods for forming the laminated structure can include application of heat and pressure as well as the use of mechanical fasteners. For example, the foam layer and/or the fiber layer can be heated to a temperature effective to soften and melt a portion thereof, which can then be laminated to one another under pressure such as by passing the stackedly arranged layers through pressure rollers.

Suitable foams for the different layers that include foam, include but are not limited to, polyurethane foams, latex foams including, natural, blended and synthetic latex foams; polystyrene foams, polyethylene foams, polypropylene foam, polyether-polyurethane foams, and the like. Likewise, one or more of the foam layers can be selected to be viscoelastic or non-viscoelastic foam. Some viscoelastic materials are also temperature sensitive, thereby also enabling the foam layer to change hardness/firmness based in part upon the temperature of the supported part. Unless otherwise noted, any of these foams may be open celled or closed cell or a hybrid structure of open cell and dosed cell. Likewise, the foams can be reticulated, partially reticulated or non-reticulated foams. The term reticulation generally refers to removal of cell membranes to create an open cell structure that is open to air and moisture flow. Still further, the foams may be gel infused in some embodiments. The different foam layers, when indicated, can be formed of the same material configured with different properties or different materials. Although the foam layers are shown having planar top and bottom surfaces, in one or more embodiments, one or more, of these surfaces can be convoluted.

The various foams suitable for use in the foam layer may be produced according to methods known to persons ordinarily skilled in the art. For example, polyurethane foams are typically prepared by reacting a polyol with a polyisocyanate in the presence of a catalyst, a blowing agent, one or more foam stabilizers or surfactants and other foaming aids. The gas generated during polymerization causes foaming of the reaction mixture to form a cellular or foam structure. Latex foams are typically manufactured by the well-known Dunlap or Talalay processes. Manufacturing of the different foams are well within the skill of those in the art.

The different properties for each layer defining the foam layer may include, but are not limited to, density, hardness, thickness, support factor, flex fatigue, air flow, various combinations thereof, and the like. Density is a measurement of the mass per unit volume and is commonly expressed in pounds per cubic foot. By way of example, the density of the each of the foam layers can vary. In some embodiments, the density decreases from the lower most individual layer to the uppermost layer. In other embodiments, the density increases. In still other embodiments, one or more of the foam layer can have a convoluted surface. The convolution May be formed of one or more individual layers with the foam layer, wherein the density is varied from one layer to the next. The hardness properties of foam are also referred to as the indention load deflection (ILD) or indention force deflection OM) and is measured in accordance with ASTM D-3574. Like the density property, the hardness properties can be varied in a similar manner. Moreover, combinations of properties may be varied for each individual layer. The individual layers can also be of the same thickness or may have different thicknesses as may be desired to provide different tactile responses.

The hardness of the foam layer generally has an indention load deflection OLD) of 7 to 16 pounds force for viscoelastic foams and an ILD of 7 to 45 pounds force for non-viscoelastic foams. ILD can be measured in accordance with ASTM D 3575. The density of the layers can generally range from about 1 to 2.5 pounds per cubic foot for non-viscoelastic foams and 1.5 to 6 pounds per cubic foot for viscoelastic foams.

The fibers utilized in the fiber layer 20 are not intended to be limited and can be natural fibers and/or synthetic fibers and/or recycled fibers. Suitable fibers include, without limitation, polyester, polyolefins such as a polypropylene and polyethylene, cellulosic fibers, cotton, rayon, wool, silk, acetate, nylon, lyocell, flax, ramie, jute, angora, kenaf, and the like, and mixtures thereof. The fibers may have varying diameter and denier, be hollow or solid, or may be crimped. Blending different types of fibers may further contribute to resiliency of the layer.

In one or more embodiments, the fiber layer can be formed from a composition including; staple fibers and binder fibers. Suitable staple fibers include, without limitation, a synthetic polymer or a natural polymer or a recycled polymer or combinations thereof selected from the group consisting of polyester, polyamide, polyolefin, cyclic polyolefin, polyolefinic thermoplastic elastomers, poly(meth)acrylate, polyvinyl halide, polyacrylonitrile, polyurethane, polylactic acid, polyvinyl alcohol, polyphenylene sulfide, polysulfone, polyoxymethylene, fluid crystalline polymer, and combinations thereof. Binder fibers are generally selected to provide adhesiveness to the layer upon application of heat. That is, the binder fibers have a lower melting point that the staple fibers such that heating a blend of staple fibers and binder fibers above the melting point of the binder fiber but below the melting point of the staple fibers results in thermal bonding within the fiber blend to form a cohesive structure.

In one or more embodiments, the fiber layer can be formed by thermal bonding using an air lay process to provide a desired amount of structural integrity to the layer. “Air-laying” is a process by which a nonwoven fibrous web layer can be formed. In the air-laying process, bundles of small fibers are separated and entrained in an air supply and then deposited onto a forming screen, usually with the assistance of a vacuum supply. The randomly oriented fibers may then be bonded to one another using, for example, thermal point bonding, autogenous bonding, hot air bonding, needle punching, calendaring, a spray adhesive, and the like. An exemplary air-laying process is taught in, for example, U.S. Pat. No. 4,640,810 to Laursen et al.

In one or more embodiments, the fibers are substantially vertically oriented fibers. By way of example, the vertically oriented fibers can be formed as described in U.S. Pat. No. 5,702,801, incorporated herein by reference. In some embodiments, the peaks of the vertically oriented fibers in the batting material may be brushed or needle punched to improve the entwining of individual fibers of one peak into adjacent peaks. Adjacent peaks of vertically oriented fibers may be of substantially the same height, or alternatively may have different heights in a repeating pattern. Multiple layers of the vertically oriented fibers can be air laid and subsequently thermally bonded to provide the desired thickness and properties.

In some embodiments, the vertically oriented fibers can be in the form of pleats as discussed above. During manufacture, once pleated, the pleated layer can be cross-needled to provide additional structural strength. The pleating can provide a pleated layer having a thickness less than about 2 inches. By means of a carding process when the fibers are laid, greater than 75%, and greater than 90% in other embodiments of the fibers of the non-woven web are aligned substantially vertically oriented relative to the plane defined by an underlying mattress or cushioning article, for example.

Due to the vertical arrangement of the fibers in the pleated layer, when a load is applied to the cushioned article, e.g., mattress, the vertical arrangement of the fibers in the layer supports the load in a spring-like manner, compressing vertically to accommodate the shape of the load without flattening in the neighboring, regions. In effect, the vertically oriented fibers, e.g., the vertically lapped formed pleats, act as vertical springs with cross needling to effect limited attachment between pleats but without causing pleats to flatten except under load. Moreover, when load is removed, the vertically oriented fibers readily recover it shape due to the independently spring-like nature of the vertically oriented fibers.

Advantageously, the vertically oriented fibers, e.g., vertically lapped formed pleats, have a low area density, which may result in lighter products and correspondingly less expensive manufacture and transport.

The hardness of the fiber layer generally has an indention load deflection (LD) of 1.0 pounds force to about 80 pounds force, although a lesser or a greater ILD may be used in some applications. In other embodiments, the hardness of the fiber layer is 30 to 60 pounds force, and in still one or more embodiments, the hardness is 40 to 50 pounds force. For reference, it has been found that a fiber layer having a hardness of about 45 pounds force correlates to a foam layer having a hardness of about 34 pounds. The fiber layer can have a density range similar to that provided in the foam layer.

The fiber layer generally includes a plurality of fibers formed into a coherent shape suitable for use in the mattress core assembly. The plurality of fibers can be mechanically and/or thermally bonded to one another to form the cohesive shape as is generally known in the art. In this regard, the fibers are not intended to be limited to any particular fiber type. The fiber layer can be formed of a single type of fiber or a blend of more than one fiber type, can be formed of fibers having the same or different lengths, can be formed of fibers having similar or different, can be formed of fibers having similar diameters or different diameters, and the like.

In one or more embodiments, the thickness of the foam layer 12 relative to the fiber layer 20 can be the same or different. Likewise, the foam and/or the fiber layer, when each is formed of multiple layers, can have the same or different thicknesses, the same or different properties, or the like. For example, the foam layer can be formed from multiple foam layers, wherein the uppermost foam layer that is most proximate to the sleeping surface is formed of a viscoelastic foam, whereas underlying foam layers are formed of non-viscoelastic foams, which may or may not include perforations, convoluted surfaces, or the like.

Optional side rails may be attached or placed adjacent to at least a portion of the perimeter of the hybrid mattress core assembly. In certain embodiments, the side rails have a firmness greater than that provided by the hybrid mattress core assembly. The side rails may be fastened to the mattress core via adhesives, thermal bonding, or mechanical fasteners.

The mattress assemblies described herein may further include additional layers and the embodiments described herein are not intended to be limited with respect to number, type, or arrangement of layers in the mattress and side rail assembly.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. 

What is claimed is:
 1. A one-sided mattress assembly, comprising: a mattress core comprising a bilayer laminate structure consisting of a foam layer and a fiber layer, wherein the foam layer is defined by one or multiple stackedly arranged foam layers and wherein the fiber layer is defined by one or multiple stackedly arranged fiber layers, wherein the mattress core is oriented such that the foam layer is proximate to a sleeping surface of the mattress assembly and the fiber layer is distally located to the sleeping surface.
 2. The one-sided mattress assembly of claim 1, wherein the fiber layer comprises polyester fibers and recycled polyester fibers.
 3. The one-sided mattress assembly of claim 1, wherein the fiber layer comprises vertically oriented fibers.
 4. The one-sided mattress assembly of claim 1 further comprising a side rail assembly disposed about at least a portion of a perimeter of the mattress core, wherein the side rail assembly is configured with a greater firmness than the mattress core.
 5. The one-sided mattress assembly of claim 4, wherein the side rail assembly has a planar top surface coplanar to a top planar surface of the mattress core.
 6. The one-sided mattress assembly of claim 1, wherein the fiber layer has an indention load deflection within a range of about 30 pounds force to 60 pounds force.
 7. The one-sided mattress assembly of claim 1, wherein the foam layer defined by multiple stackedly arranged foam layers comprise different properties.
 8. The one-sided mattress assembly of claim 1, wherein the foam layer defined by multiple stackedly arranged foam layers comprise different materials.
 9. The one-sided mattress assembly of claim 1, wherein the foam layer defined by multiple stackedly arranged foam layers comprises a viscoelastic foam layer proximate to the sleeping surface.
 10. A two-sided mattress assembly, comprising: a mattress core comprising a trilayer laminate structure consisting of a fiber layer sandwiched between first and second foam layers, wherein the fiber layer is defined by one or multiple stackedly arranged fiber layers, wherein the first foam layer is defined by one or multiple stackedly arranged foam layers, and wherein the second foam layer is defined by one or multiple stackedly arranged foam layers.
 11. The two-sided mattress assembly of claim 10, wherein the fiber layer comprises polyester fibers and recycled polyester fibers.
 12. The two-sided mattress assembly of claim 10, wherein the fiber layer comprises vertically oriented fibers.
 13. The two-sided mattress assembly of claim 10 further comprising a side rail assembly disposed about at least a portion of a perimeter of the mattress core, wherein the side rail assembly is configured with a greater firmness than the mattress core.
 14. The two-sided mattress assembly of claim 13, wherein the side rail assembly has a planar top surface coplanar to a top planar surface of the mattress core.
 15. The two-sided mattress assembly of claim 10, wherein the fiber layer has an indention load deflection within a range of about 30 pounds force to 60 pounds force.
 16. The two-sided mattress assembly of claim 10, wherein the foam layer defined by multiple stackedly arranged foam layers comprise different properties.
 17. The two-sided mattress assembly of claim 10, wherein the foam layer defined by multiple stackedly arranged foam layers comprise different materials.
 18. The two-sided mattress assembly of claim 10, wherein the foam layer defined by multiple stackedly arranged foam layers comprises a viscoelastic foam layer proximate to the sleeping surface.
 20. A mattress assembly comprising: a mattress core; an upholstery layer overlaying the mattress core comprising a bilayer laminate structure consisting of a foam layer and a fiber layer, wherein the foam layer is proximately located to a sleeping surface of the mattress assembly and the fiber layer is distally located to the sleeping surface; and a fabric ticking layer encapsulating the mattress core and the upholstery layer to form the mattress assembly.
 21. The mattress assembly of claim 20, wherein the foam layer comprises a viscoelastic foam.
 22. The mattress assembly of claim 20, wherein the fiber layer comprises a vertically oriented fiber. 